Biodegradable Produce Enclosure

ABSTRACT

A mesh basket ( 100 ) is described that includes a rigid lattice structure ( 102 ) having a fibrous side and bottom. The structure has a plurality of lattice elements ( 110 ) that can collectively define a plurality of visually non-occluded lattice holes ( 112 ), such that a consumer can view the contents of the basket. Preferably, the apparent collective area of the holes is at least 40% of the apparent collective area of the lattice structure ( 102 ). The basket ( 100 ) can also have a film layer ( 120 ) covering at least a portion of the basket to thereby regulate moisture within the basket ( 100 ).

The application claims priority to U.S. provisional patent applicationwith Ser. No. 61/221188 filed on Jun. 29, 2009. This and all otherextrinsic materials discussed herein are incorporated by reference intheir entirety. Where a definition or use of a term in an incorporatedreference is inconsistent or contrary to the definition of that termprovided herein, the definition of that term provided herein applies andthe definition of that term in the reference does not apply.

FIELD OF THE INVENTION

The field of the invention is produce enclosures.

BACKGROUND

The modern world currently produces massive amounts of waste. Much ofthe waste comes from plastic and/or metal, which decomposes at a veryslow rate. These materials must be recycled, dumped into the oceans orwaterways, or deposited into landfills where they will remain forcenturies.

In order to reduce the waste in our ever-filling landfills, it isadvantageous to create containers that are biodegradable and/orcompostable. However, produce is being increasingly packaged usingplastic “clamshell” packaging to solve distribution and retail issues,such as to provide a complete view of the contents to allow consumers toview the contents at the point of sale. Such clamshell packaging isproblematic for perishable items such as produce that require a certainrange of moisture, as the packaging fails to provide precise control ofinternal moisture, which often accelerates spoilage of the contents.

Clamshell packaging (e.g., U.S. Pat. No. 6,845,878 to Hayes) can also beproblematic in that consumers increasingly see plastic as ecologicallyirresponsible and often unwilling to purchase contents in suchpackaging.

While plastic baskets are also used such as those used for various typesof berries, such packaging is generally not biodegradable and increasesthe waste in the landfills.

It is known to have paper produce containers, and exemplary containersare discussed in U.S. Patent Appl. No. 2008/0302808 to Maxwell, JapanesePatent No. 6156469 filed on Nov. 26, 1992, U.S. Pat. No. 4982872 toAvery; and WIPO Patent Appl. No. 2008/076075 to Lim, et al. Althoughbiodegradable for the most part, the paper containers known to Applicantsuffer from similar disadvantages as the plastic clamshell packaging.

Thus, there is still a need for a biodegradable container that allowconsumers to view the container's contents from multiple sides at thepoint of sale, while also precisely controlling the container's internalmoisture.

SUMMARY OF THE INVENTION

The inventive subject matter provides apparatus, systems and methods inwhich an enclosure for housing produce or other perishable itemscomprises a mesh basket having a rigid lattice structure that includesat least a side and a bottom. As used herein, the term “produce” meansfruit, vegetables, and other agricultural goods. Other items (e.g.,non-edible items) are also contemplated.

The structure includes a plurality of lattice elements that collectivelydefine a plurality of visually non-occluded lattice holes. As usedherein, the term “lattice” includes both regular and irregular patterns.As used herein, the term “non-occluded” means at least 70% of visiblelight passes through the lattice hole at normal room intensity, andtherefore includes slightly opaque, or at least as much light as passesthrough a non-tinted glass window. For example, the lattice could have astructure comprising squiggle-shaped lattice elements or a structurehaving a higher density of lattice elements in one area compared withthe surrounding area. Alternatively, the lattice could have a regularstructure including, for example, a pattern of diamond-shaped orsquare-shaped lattice elements.

In preferred embodiments, the apparent collective area of the latticeholes is at least 40%, more preferably, at least 50%, and mostpreferably, at least 60% of the apparent collective area of the latticestructure. As used herein, the “apparent surface area” of the basket isthe outside surface area of the basket's sides, walls, and optional top.Thus, for example, even if the basket had a concave bottom, the entireconcave outer surface of the bottom would be included in the basket'sapparent surface area. However, the side wall of each lattice hole, ascompared to the outside surface of the lattice elements, is not includedin the basket's apparent surface area. In addition, the apparent surfacearea would not include an open top, such as if the basket lacked a lidor other closure.

Unless the context dictates the contrary, all ranges set forth hereinshould be interpreted as being inclusive of their endpoints andopen-ended ranges should be interpreted to include only commerciallypractical values. Similarly, all lists of values should be considered asinclusive of intermediate values unless the context indicates thecontrary.

Optionally, the basket can have one or more film layers that preferablycover at least 100 cm² of the apparent collective area of the latticeholes. Preferably, the film layers are essentially transparent, althoughtranslucent film is also contemplated.

Various objects, features, aspects and advantages of the inventivesubject matter will become more apparent from the following detaileddescription of preferred embodiments, along with the accompanyingdrawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a perspective view of an embodiment of a basket.

FIGS. 2-4 are top views of alternative embodiments of a basket.

FIG. 5 is a side view of another embodiment of a basket having a top.

DETAILED DESCRIPTION

In FIG. 1, a mesh basket 100 is shown for housing produce. The basket100 can include a rigid lattice structure 102 forming at least a side104 and a bottom 106, however, it is contemplated that the side wall 104can have a different lattice structure than the bottom 106. Optionally,the structure 102 can also comprise a top (not shown).

Preferred baskets 100 have a structure 102 sufficiently rigid to protectthe internal contents of the basket 100 from being crushed, and includea closed bottom 106, an open top 108, and a fibrous side wall 104. It isdesirable for the basket 100 to withstand a weight of up to 50 lbswithout significant deformation. Preferably, the basket can withstand atleast 5 lbs, at least 10 lbs, at least 15 lbs, at least 20 lbs, and morepreferably at least 30 lbs of force without significant deformation. Asused herein, “fibrous side wall” means a wall comprising a fibrousmaterial as a significant structural constituent. The fibrous wallcontemplated herein preferably has at least 2, 5, 10, 20 or even 30 dryweight percent of fibers. Preferably, the fibrous wall has at least 80or 90 dry weight percent of fibers.

As used herein “fibrous material” means materials characterized by aplurality of discrete fibers. The filaments can be plant or animalderived, synthetic, or some combination of these. In “plant-derivedfibrous materials” the filaments are at least predominantly of plantorigin, examples of which include wood, papyrus, rice, ficus, mulberry,fibers, cotton, yucca, sisal, bowstring hemp and New Zealand flax. Paperis generally a fibrous material that is usually made by pressing andde-watering moist fibers, typically cellulose pulp derived from woodrags, or grasses.

The basket 100 is advantageously composed of one or more biodegradablematerials including, for example, die cut paper, chipboard that has beenglued, molded fiber, and other fibrous materials. As used herein, a“biodegradable material” means a material that will break down to atleast 90% H₂O, CO₂, and biomass within a period of six months from theaction of naturally occurring micro-organisms such as bacteria, fungi,algae etc. under favorable conditions. For example, meat, plants, wood,cotton, animal protein, and paper are all deemed herein to bebiodegradable.

The basket 100 has a rectangular cross-section, but it is contemplatedthat the basket could have a circular, elliptical, or any othercommercially suitable horizontal cross-section.

The lattice structure 102 preferably includes a plurality of latticeelements 110 that compose the structure 102. Each of the latticeelements 110 define at least a portion of a lattice hole 112, andcollectively define a plurality of lattice holes 112. Preferred latticeholes 112 are visually non-occlusive. The non-occluded lattice holesadvantageously allow the contents of the baskets to be viewed from thetop and the bottom without requiring removal of the contents from thebasket and without requiring opening of the container when a lid ispresent.

In preferred embodiments, the apparent collective area of the latticeholes is at least 20%, more preferably at least 40%, and most preferablyat least 50%, of the apparent collective area of the lattice structure.

As shown in FIG. 1, the lattice elements define a regular patterncomprising a plurality of lattice holes having a rectangular shape.However, it is contemplated that the lattice elements could define otherregular patterns including, for example, diamond-shaped holes, circularor ovular holes, or other sized and dimensioned holes, as well asirregular patterns including, for example, those shown in FIGS. 3-4.

It is contemplated that the lattices structure could vary in number,size and dimension depending on the basket's use and the desiredstrength and rigidity of the basket. Thus, for example, a basket forstrawberries might have lattice holes with smaller dimensions than abasket for apples. In addition, the lattice holes can be of anycommercially-suitable size and shape including, for example, circles,squares, and rectangles.

As shown in FIG. 1, the basket 100 can include a film layer 120 thatcovers at least a portion, and preferably, at least 100 cm² of theapparent collective area of the lattice holes, and more preferably, atleast the top portion of the basket 100. The film layer 120 ispreferably transparent, or at least translucent, such that a consumercan view the contents of the basket 100 through the film layer 120. Thisis beneficial as the film layer(s) helps prevent insects and other pestsfrom reaching the contents while maintaining a desired level of moisturewithin the basket 100. The film layer 120 is preferably attached to thebasket 100 using an adhesive, although any commercially suitablefastener could be used.

The film layer 120 preferably comprises a water permeability sufficientto resist water for the expected useful life of the basket 100, andpreferably at least 14 days, and more preferably up to 28 days. Further,the film layer 120 may have perforations or holes to allow sufficientair flow to ensure maximal freshness of the intended contents of thebasket 100.

Although film layer 120 could be used to cover the open spaces of thebasket 100, the basket 100 could alternatively have additional filmlayers such that the open spaces of the basket 100 are covered by thefilm layers. For example, a first film layer could be used to cover abottom 106 and side 104 of the basket 100. Then once the contents areplaced in the basket 100, a second film layer can be provided to enclosethe contents within the basket 100. Such additional film layer can befastened to the basket by an adhesive or other commercially suitablefastener(s). Alternatively or additionally, a rubber band could be usedto retain the film layer(s) 120. In this instance, and where other upperlimits are not expressly stated, the reader should infer a reasonableupper limit. In this instance, for example, a commercially reasonableupper limit is about ten.

Preferred film layer(s) are composed of one or more biodegradablematerials such that the layer(s) provide for a semi permeable, and atleast partially transparent, moisture barrier. This advantageouslyallows for precise moisture control of the basket's contents. The filmlayers will depend on the contents of the basket and the externalenvironment to which the basket is subjected. Preferred films includethose manufactured by, for example, Maverick™, Bloomer Plastics™,Natural Flexible™, Evlon®, and EarthFirst® PLA.

At least a portion of the inner surfaces of the basket 100 canadvantageously include a permeation barrier material to reduce thetransfer rate of the surfaces and thereby retain the rigidity of thebasket. As used herein, a statement that a surface “includes apermeation barrier material” means that the surface is treated with anadditive that has a transfer rate of less than or equal to 50 μl ofwater and/or sunflower oil per cm2 per six-month period of time at roomtemperature and normal atmospheric pressure (STP).

Preferred permeation barriers comprise vegetable or petroleum wax,vulcanized latex, plant resins, and cellophane. Other suitablepermeation barrier materials include those disclosed in U.S. Pat. No.7,344,784 to Hodson or US20050130261 to Wils.

FIG. 2 illustrates another embodiment of a mesh basket 200 having arigid lattice structure 202 forming at least four sides 204 and a bottom206. With respect to the remaining numerals in FIG. 2, the sameconsiderations for like components with like numerals of FIG. 1 apply.

In FIG. 3, an alternative embodiment of a mesh basket 300 is shownhaving an irregular lattice structure 302. With respect to the remainingnumerals in FIG. 3, the same considerations for like components withlike numerals of FIG. 1 apply.

FIG. 4 illustrates yet another embodiment of a mesh basket 400 having anirregular lattice structure 402 composed of strings 410, which form aplurality of lattice holes 412. With respect to the remaining numeralsin FIG. 4, the same considerations for like components with likenumerals of FIG. 1 apply.

FIG. 5 illustrates yet another embodiment of a mesh basket 500 having atop 530 with a second lattice structure 532 having a plurality oflattice holes 534. Although the lattice structure 502 of the mesh basket500 is the same as the lattice structure 532 of the top 530, it is alsocontemplated that the lattice structures 502 and 532 could be different.The top can have a clamshell configuration or other commerciallysuitable configurations. With respect to the remaining numerals in FIG.5, the same considerations for like components with like numerals ofFIG. 1 apply.

It should be apparent to those skilled in the art that many moremodifications besides those already described are possible withoutdeparting from the inventive concepts herein. The inventive subjectmatter, therefore, is not to be restricted except in the spirit of theappended claims. Moreover, in interpreting both the specification andthe claims, all terms should be interpreted in the broadest possiblemanner consistent with the context. In particular, the terms “comprises”and “comprising” should be interpreted as referring to elements,components, or steps in a non-exclusive manner, indicating that thereferenced elements, components, or steps may be present, or utilized,or combined with other elements, components, or steps that are notexpressly referenced. Where the specification claims refers to at leastone of something selected from the group consisting of A, B, C . . . andN, the text should be interpreted as requiring only one element from thegroup, not A plus N, or B plus N, etc.

1. A mesh basket, comprising: a rigid lattice structure having a fibrousside and bottom, the structure comprising a plurality of latticeelements that collectively define a plurality of visually non-occludedlattice holes; and wherein the apparent collective area of the holes isat least 40% of the apparent collective area of the lattice structure.2. The basket of claim 1, further comprising a film layer covering atleast 100 cm² of the apparent collective area of the lattice holes. 3.The basket of claim 2, wherein the film layer covers the bottom of thelattice structure.
 4. The basket of claim 2, wherein the film layer isessentially transparent.
 5. The basket of claim 2, wherein the filmlayer is biodegradable.
 6. The basket of claim 1, further comprising afibrous top removably coupled to the lattice structure.
 7. The basket ofclaim 1, wherein the lattice structure comprises a pulp-molded body. 8.The basket of claim 1, wherein the lattice structure comprises apaperboard.
 9. The basket of claim 1, wherein at least one of thelattice holes has an area of at least 4 cm².
 10. The basket of claim 1,further comprising a window having a surface area of at least 9 cm². 11.The basket of claim 1, wherein the lattice structure is configured towithstand a force of 10 pounds without deformation.
 12. The basket ofclaim 1, wherein the apparent collective area of the holes is at least50% of the apparent collective area of the lattice structure.